A development example of a foam insert intended to fill internal space in equipment while keeping added weight low. The project reached a white 3D-printed prototype and a black CNC-machined PE foam pilot at 20 kg/m³, made to assess the feasibility and conditions for EPE production. It did not proceed to mass production.
Discuss a similar application
The intended function is to occupy internal equipment space with a lightweight filler. Similar applications can be explored for drone bodies, machines, vehicle housings, robotic systems and industrial equipment. Define the available envelope, neighboring components and the access that the filler must leave clear.
A white prototype was produced by 3D printing as a physical model of the component. It represents the prototype stage of the project. Foam material assessment belongs to the separate PE pilot stage.
The black pilot was CNC machined from PE foam at 20 kg/m³. Its purpose was to assess EPE production ability and the associated feasibility conditions. CNC machining is the confirmed process for this pilot; the intended EPE production route is a separate development step.
The project did not progress to mass production. This example presents the prototype and pilot stages, together with the production direction considered. Further project details remain confidential; no confirmed EPE production conditions or performance test results are reported.
Start with the equipment drawing or CAD, the volume to fill, the permitted added mass and the interfaces that must remain accessible. Identify assembly and removal needs, operating conditions, target quantities and the checks required before production. These are considerations for your project, to be agreed with FFG around its own specification.
Share the part or assembly drawing, overall dimensions, material or grade if known, interfaces, quantities and timing. Include the requirements you need to validate.
Discuss a similar application